I D card intermediate and method

ABSTRACT

An I D card intermediate which includes a business form having one or more I D cards diecut into it and backed by a laminate of multi-ply film.

This application is a continuation of application Ser. No. 08/159,294,filed Nov. 30, 1993 now abandon.

BACKGROUND AND SUMMARY OF INVENTION

This invention relates to an I D card intermediate and method and, moreparticularly to an intermediate which includes a two film ply laminateon a length of card-providing paper.

Currently, I D cards as provided by the sponsoring company-store,insurance company, etc. --are provided as part of a business form anddetachable therefrom by the intended user. These card-equipped forms areof two types. One type has the card "tipped on", i e adhesively securedto one surface. This has the disadvantage of developing a substantialthickness so that laser printing, for example, is virtually prohibited.The other tip has a sheet perforated to define an I D card. Althoughthis avoids the thickness problem, it substitutes another in the form ofthe perforation bonds which give the card a rough feeling edge. Bothproblems are avoided by the invention.

According to the invention, an I D card intermediate is provided whichincludes a length of paper having top and bottom surfaces and agenerally rectangular die cut extending therethrough between thesurfaces to define an I D card. A film laminate is adhesively secured tothe rear surface and extends beyond the diecut on all sides thereof. Thelaminate also includes two film layers adhesively united in superposedrelation with a first of the film layers being positioned adjacent thebottom surface and a second of the film layers being positioned remotefrom the bottom surfaces. The diecut extends through the first filmlayer but not the second film layer and the paper length top surfacewithin the diecut is equipped with first and second printed indiciawithin the diecut. The first printed indicia relates to the sponsor ofthe I D card and the second printed indicia relating to the identity ofthe intended user of the I D card.

The invention also includes a method for making an I D card intermediatewhich include the steps of providing a two ply film laminate arranged inface-to-face relation with a rupturable adhesive therebetween and alsoproviding a length of paper having opposed surfaces with printed indiciarelating to an I D card sponsor on one of the surfaces. The stepsfurther include adhesively uniting the laminate to the other of thesurfaces to position a first of the film plies adjacent the othersurface, diecutting the paper length and the first of the film plies toprovide a generally rectangular closed perimeter cut defining an I Dcard, and imprinting printed indicia on the one surface. The imprintedindicia relates to the identity of the intended user of said I D card.Thus, the invention provides advantages both structurally and in themethod of making over the prior art.

BRIEF DESCRIPTION OF DRAWING

The invention is described in conjunction with the accompanying drawing,in which

FIG. 1 is a perspective view of a fragmentary string of form lengthsconstructed according to teachings of the invention;

FIG. 2 is an enlarged fragmentary cross sectional view taken along thesight line 2--2 as applied to FIG. 1; and

FIG. 3 is a schematic side elevational view of apparatus practicing themethod of the invention.

DETAILED DESCRIPTION

Generally speaking, the invention makes use of a business form (eithersheeted or continuous with line holes) having one or more I D cardsincorporated in it.

Referring to FIG. 1, the numeral 10 designates generally a string ofinterconnected business form lengths as at 11, 11a, 11b, etc. Each formlength is defined between transverse lines of perforation as at 12 andmay be equipped, at least along one longitudinal edge, with line holesas at 13.

The I D card is generally designated 14 and is defined by a closedperimeter of diecut 15 which generally defines a rectangular outline.

The form length 11 generally has two types of printed indicia thereon.One type of printed indicia designated 16 has to do with the sponsor ofthe card and may also be present as at 17 in one portion of the I D card14. The second type of printed indicia is designated 18 and relates tothe intended user of the card--the I D information--and this is normallyonly on the card itself.

The construction according to the invention makes use of the form length11 as seen in FIG. 2 and has an upper surface 19 and a lower surface 20.Applied to the lower surface 20 is a pressure sensitive adhesive 21which makes it possible to apply a laminate generally designated 22 tothe surface 20 of the form 11. The laminate 22 includes first and secondtransparent films as at 23 and 24 joined together by a dry adhesive 25.This adhesive is readily rupturable to operate the film plies. Such alaminate is commercially available from 3-Sigma located at Columbia,S.C. under Product No. 90906-546. Such a laminate has been used in thepast in connection with coupon-bearing business forms.

Also seen in FIG. 2 is the diecut 15 which is seen to extend from thetop surface 19 of the form 11 down to but not through the bottom film24. Thus, when the intended user's information is applied to the card,the card is conveniently removed and has a rear film as at 23 to stiffenthe same. In many instances, it is desirable to provide at least two I Dcards and this version is depicted in FIG. 1.

There are a number of advantages stemming from this constructionincluding the card being made from the form so as to permit registrationbetween the form and the I D card to be exact.

Secondly, any type of paper can be used to produce the form such as 20pound bond, 100 pound tag, etc.

Thirdly, as pointed out above, the back of the card has the film 23laminated thereto so that this helps make the cards strong and durable.

Fourthly, since the form is the card, the height difference between theform and the card is minimal--of the order of a mil or so and this helpswhen the forms are in a pack and when running on a laser printer.

INVENTIVE METHOD

In general, this makes use of a commercially available coupon stockapplied in a patch on the back of the form using a pressure sensitiveadhesive. The form is then diecut from the front side over this patch.The diecut is continuous with no bonds in it and the shape of the diecutis that of a typical I D card--usually with rounded corners. The diecutgoes through all the sheets of material down to the last ply of film ofthe laminate 22. After the form is printed on any type printer, the I Dcard can be removed from the form.

The inventive method is shown in greater detail in FIG. 3 and referenceis made thereto. Starting at the extreme right of FIG. 3, the numeral 10again designates generally the length of paper which provides the formlengths 11 and also has surfaces 19 and 20. However, these surfaces arereversed from the showing in FIG. 2--the laminate patch 22 being appliedto the upper surface as seen in FIG. 3. This is a matter ofconvenience--although normally applying operations are performed fromabove.

Above the horizontal path along which the paper web 10 travels is anunwind 26 which is equipped with coupon stock film, i.e., the laminate22. Inasmuch as this is purchased commercially, it is equipped with thepressure sensitive adhesive 21 and overlying that is a release liner 27which is continuously removed from the coupon stock emanating from theunwind 26. The no longer needed release liner 27 is then rewound into aroll 28 for disposition.

The laminate has the pressure-sensitive adhesive 23 facing upwardly andthis is exaggerated at the right of FIG. 3 for ease of understanding.The web unwound from the parent roll 26 passes over a rotating vacuumroll 29 which is rotating faster than the web being unwound from theroll 26--there being a sliding contact between the web and the roll 29.Ranged next to the vacuum roll 29 is a cutoff roll 30 which is seen tosever the web and adhesive into discrete patches 22. Then, these arespaced longitudinally be virtue of the faster speed of the vacuum roll29. The laminates 22 are adhered to the web 10 by virtue of thepressure-sensitive adhesive being in face-to-face contact with the web10. Thereafter, the web encounters the diecutting station generallydesignated 31 and which includes an anvil roll 32 and a die roll 33.This provides the cutout after which the forms can be transverselyperforated by the perforator generally designated 34 to define theacross perforation lines 12.

Thereafter, the continuous form string may be zig-zag folded as at 35and transported to a second site 35' where it is printed by printer 36with the information specific to the intended user.

While in the foregoing specification a detailed description of anembodiment of the invention has been set down for the purpose ofillustration, many variations in the details hereingiven may be made bythose skilled in the art without departing from the spirit and scope ofthe invention.

I claim:
 1. A method for making an I D card intermediate comprisingperforming at a first site the steps of providing a two ply filmlaminate arranged in face-to-face relation with a dry, rupturableadhesive therebetween, providing a length of paper having top and bottomsurfaces with first printed indicia relating to an I D card sponsor onsaid top surface, adhesively uniting said laminate to said bottomsurface to position a first of said film plies adjacent said bottomsurface, diecutting said paper length and said first of said film pliesto provide a generally rectangular closed perimeter cut defining an I Dcard having said first film ply attached thereto with said film laminateextending beyond said diecut on all sides thereof, performing at asecond site the step of laser imprinting second indicia on said topsurface relating to the identity of the intended user of said I D cardwith both said first and second indicia being within said diecut andremoving said I D card and said first film by rupturing said dryadhesive.
 2. An I D card intermediate comprising a length of paperhaving top and bottom surfaces and a generally rectangular diecutextending therethrough between said surfaces to define an I D card, afilm laminate adhesively secured to said bottom surface and extendingbeyond the diecut on all sides thereof, said laminate including two filmlayers adhesively united in superposed relation with a first of saidfilm layers being positioned adjacent said bottom surface and a secondof said film layers being positioned remote from said bottom surface,said diecut extending through said first film layer but not said secondfilm layer, said paper length top surface within said diecut beingequipped with first and second printed indicia within said diecut, saidfirst printed indicia relating to the sponsor of said I D card and saidsecond printed indicia relating to the identity of the intended user ofsaid I D card, said paper adhesive being interposed between said firstand second film layers, said dry adhesive being rupturable upon exertionof a removal force on said I D card whereby said first film layerremains with said I D card when said I D card is removed from said paperlength.
 3. An I D card intermediate comprising a length of paper havingtop and bottom surfaces and a generally rectangular diecut extendingtherethrough between said surfaces to define an I D card, a filmlaminate adhesively secured to said bottom surface and extending beyondthe diecut on all sides thereof, said laminate including two film layersadhesively united in superposed relation with a first of said filmlayers being positioned adjacent said bottom surface and a second ofsaid film layers being positioned remote from said bottom surface, saiddiecut extending through said first film layer but not said second filmlayer, said paper length top surface within said diecut being equippedwith first and second printed indicia within said diecut, said firstprinted indicia relating to the sponsor of said I D card and said secondprinted indicia relating to the identity of the intended user of said ID card, said paper length top surface outside said diecut also beingequipped with said first printed indicia but not said second printedindicia, a dry adhesive being interposed between said first and secondfilm layers, said dry adhesive being rupturable upon exertion of aremoval force on said I D card whereby said first film layer remainswith said I D card when said I D card is removed from said paper length.